In an exclusive interview with BioPharma APAC, Mr. Brendan O’Callaghan, Executive Vice President, Manufacturing & Supply at Sanofi, sheds light on the game-changing modular design of the Singapore Modulus facility. From its innovative “plug-and-produce” approach to supporting Sanofi’s sustainability goals and strengthening the global supply chain, the facility is poised to redefine biopharmaceutical manufacturing. Discover how this state-of-the-art site is boosting pandemic preparedness, advancing green technologies, and shaping Singapore’s biopharma workforce and ecosystem.

How does the modular design of the Modulus facility enhance flexibility in vaccine and biopharmaceutical production?

Modulus’ flexibility stems from its unique design, featuring 34 independent configurable “mini factories.” These standardised modules are equipped with interconnected, modular equipment. When a product change is needed, instead of overhauling an entire facility, individual modules can be quickly reconfigured with the necessary equipment and process controls.

This “plug-and-produce” approach allows for rapid reconfiguration of production lines based on demand. This can be done in a matter of days, significantly faster than the industry standard of several weeks or months. This ensures minimal downtime and maximal production efficiency.

Modulus can be adapted to manufacture up to four vaccines or biopharmaceuticals simultaneously and can be reconfigured in a matter of days to change over between pre-established technological platforms (live attenuated viral or recombinant protein vaccines, as well as biotechnology derived treatments such as enzymes or monoclonal antibodies).

What role will Modulus play in accelerating pandemic preparedness and response?

Modulus can be adapted to manufacture up to four vaccines or biopharmaceuticals simultaneously and can be reconfigured in a matter of days to change over between pre-established technological platforms, compared with several weeks or months in more conventional plants.

This is critical for critical public health needs such as pandemic preparedness. Its flexible design and rapid changeover capability between pre-established technological platforms in just a few days or weeks enables a swift response to future pandemics by quickly adapting to produce vaccines or therapeutics as needed.

The COVID-19 pandemic highlighted the need for agile and scalable manufacturing capabilities, and Modulus directly addresses this need.

How does this facility align with Sanofi’s Net Zero commitments and sustainability goals?

The facility serves as a testament to Sanofi's dedication to sustainability, featuring green technology such as the use of solar panels, green electricity, and recycled materials in its construction, including:

• Digital technologies that help optimise production efficiency and provide live monitoring of manufacturing processes, so energy can be managed and tracked according to our goals.
• The use of green bitumen incorporating 10% recycled hard plastic from Sanofi's EpiPen injectors in partnership with Magorium.
• The facility adheres to Sanofi's global zero-landfill waste policy, with a 2025 target for over 90% of waste being reused, recycled, or recovered.

Dedicated programs will monitor key metrics like energy consumption, water usage, and waste generation, benchmarked against Sanofi's global 2045 net-zero carbon emissions target. Regular audits and reporting will ensure transparency and accountability.

What advanced technologies and digital innovations are being utilised in the Modulus facility?

From the piloting of novel pilling technique during the construction phase, the implementation of IT/OT architecture and plug-and-play concept in our facility, to eventually a first in Singapore virtual TOP approval process in collaboration with BCA.

This includes the implementation of advanced process control systems, real-time data analytics for predictive maintenance and quality control, and machine learning algorithms for process optimisation. For example, AI is used to analyse vast datasets to identify patterns and optimise parameters such as temperature, pH, and nutrient levels, leading to increased efficiency and reduced batch failures, and the use of automated guided vehicles and conveyor belt systems.

How does the Singapore Modulus site complement Sanofi’s global manufacturing network?

The Singapore Modulus facility represents a significant addition to Sanofi's global manufacturing network, providing a strategically located and technologically advanced hub in the Asia-Pacific region. This state-of-the-art site, with its unique modular design and cutting-edge technologies, offers flexible and rapid production capabilities for a wide range of biopharmaceuticals, complementing existing Sanofi facilities and bolstering our ability to respond to evolving global health needs.

The Singapore Modulus facility also plays a vital role in strengthening the resilience of Sanofi's global supply chain. By diversifying manufacturing locations, we mitigate risks associated with geopolitical instability, natural disasters, or other unforeseen disruptions. This distributed approach ensures greater security of supply and reduces dependence on any single manufacturing site.

What are the long-term implications of this facility for Singapore’s biopharma ecosystem and workforce development?

Modulus will create approximately 200 highly skilled jobs in Singapore, in areas such as biopharma manufacturing, process engineering, automation engineering, AI/machine learning, quality control, and supply chain management. Sanofi offers global training programs in various areas, including biomanufacturing and digital technologies. We are exploring how best to leverage these programs and other development opportunities to upskill Modulus Singapore employees in advanced manufacturing technologies, AI, and data analytics.

In Singapore, we have our Career Conversion Programme (CCP) for biomedical manufacturing technicians. Sanofi has already hired 14 individuals through the CCP. We are strongly committed to investing in Singapore's future workforce and strengthening our biopharmaceutical capabilities at every level. 

Beyond direct employment, the facility is expected to stimulate growth within Singapore's biopharma ecosystem by attracting further investment, fostering collaboration with local research institutions and startups, and contributing to the development of a skilled talent pool in advanced biomanufacturing. This will strengthen Singapore's position as a leading hub for biopharmaceutical innovation and manufacturing in the region.